Performance of serial assembly line designs under unequal operator speeds and learning

Abstract

The traditional balanced assembly line designs can perform quite inefficiently under the presence of high labor turnover, low operator learning rates, and stochastic processing times. In these situations assembly line designs based on dynamic work allocation and work sharing principles have been shown to render a higher and less variable throughput. However, for situations where low labor turnover conditions and high operator learning rates exist, the traditional balanced lines still tend to be most productive. This paper has two objectives: to introduce a method based on work sharing principles, which we denominate Modified Work Sharing (MWS), and to develop some simple analytical tools that will allow us to compare the performance of this method with the traditional and other dynamic work allocation line designs. These results suggest that the traditional method is the most affected by the introduction of new operators in the production lines and thus the most affected by variability in general. On the other hand, dynamic work allocation methods appear to better absorb the variability introduced by new operators by sharing the workload of new operators with the more experienced members of the line.

Keywords:

• Labor turnover
• Dynamic work allocation
• Serial assembly lines
• Active operator replacement
• Learning curves

Acknowledgements

The authors would like to acknowledge the support provided by the National Science Foundation through the grant DMI-0100370 for the realization of this work.